PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE HEAT EXCHANGER PLATES IN 206-6476 HEAT EXCHANGER ON CERTAIN 3512B MARINE ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE HEAT EXCHANGER PLATES IN 206-6476 HEAT EXCHANGER ON CERTAIN 3512B MARINE ENGINES

Usage:

REBE4644-00

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16Dec2008

U-644

O-587

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE HEAT EXCHANGER PLATES IN 206-6476 HEAT EXCHANGER ON CERTAIN 3512B MARINE ENGINES
1379		PI31601

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31601" as the Part Number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. Exception: If the repair is done after failure, use "PI31601" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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NOTE:

The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.

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COMPLETION DATE	TERMINATION DATE
30Jun2009	31Dec2009

PROBLEM

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The heat exchanger plates need to be re-oriented on certain 3512B Marine Engines. The existing orientation of the plates can cause high engine water temperature.

AFFECTED PRODUCT

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Model	Identification Number
3512B	MKH00206-00207, 230-231, 238-240, 242, 248-249

PARTS NEEDED

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No parts needed for this program

ACTION REQUIRED

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Remove heat exhanger from engine and restack plates in different orientation. Refer to the attached Rework Procedure.

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OWNER NOTIFICATION

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U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 6.0-hour job

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PARTS DISPOSITION

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Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

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COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE HEAT EXCHANGER PLATES IN THE 206-6476 HEAT EXCHANGER ON CERTAIN 3512B MARINE ENGINES

MODELS INVOLVED - 3512B Marine Engines

Dear Caterpillar Product Owner:

The heat exchanger plates need to be re-oriented on the products listed below. The existing plate orientation can cause high water temperature. You will not be charged for the service performed.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

Please refer the dealer to their Service Letter dated 16Dec2008 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to 16Dec2008 Service Letter

Rework Procedure

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Refer to the appropriate service manual as necessary.

Drain the fluid in the heat exchanger as required. Remove the heat exchanger from the engine, refer to the removal and installation procedure described in Special Instruction REHS2599 (Cleaning the Engine Mounted Heat Exchanger). Reorient the heat exchanger plate per the following instructions. Reinstall the heat exchanger to the engine per the Special Instruction REHS2599 and the D&A Manual.

PLATE TYPE HEAT EXCHANGER PLATE RE-ORIENTATION PROCEDURE

Caution:

The heat exchanger weighs approximately 36 kg (80 lb). Use a suitable lifting device before attempting to begin the removal of the heat exchanger.

NOTE: The plates may have sharp corners

1) Remove the 2- 5/8 inch bolts, washers and aluminum spacers per REHS2599 Special Instructions.

2) Loosen the remaining 8 bolts from the front frame in small increments to keep frame plates level throughout the process. Plates should not vary from level by more than 1/2 inch.

3) Remove the first 2 plates from the heat exchanger. Keep them in a stack and label them "stack #1" and label the individual plates 1 and 2.

4) Separate plate 3 and label as plate 3.

5) Separate plate 4 and label as plate 4.

6) Separate plate 5 and label as plate 5.

7) Remove plates 6 thru 21 from the heat exchanger. Keep them in a stack and label the stack "stack #2" and label the individual plates 6 thru 21.

8) Remove plates 22 thru 29 from the heat exchanger. Keep them in a stack and label the stack "stack #3" and label the individual plates 22 thru 29.

9) Separate plate 30 and label as plate 30.

10) Separate plate 31 and label as plate 31.

11) Remove plates 32 thru 52 from the heat exchanger. Keep them in a stack and label the stack "stack #4" and label the individual plates 32 thru 52. Plate #33 is called a "partition" which has no chevrons or gasket.

12) Remove plates 53 thru 67 from the heat exchanger. Keep them in a stack and label the stack "stack #5" and label the individual plates 53 thru 67.

13) Remove plate 68 from the heat exchanger. Label as plate 68.

Restacking The Plates:

NOTE: Refer to Images 1.1.1 thru 1.5.1 to assist with correct plate and gasket orientation.

Place the pressure plate face down with the holes at the top.

1) Pick "stack #1" and orient with plate 1 facing towards the pressure plate with the chevron facing towards the right looking down on the plate.

2) Plate should have the chevron facing left looking down on the plate.

3) Install "plate 4" onto the plate stack with the chevron facing right.

4) Install "plate 3" onto the plate stack with the chevron facing left.

5) Install "stack #2" on top of plate #3 with the chevron of the first plate (#6) in the stack facing right.

6) Install "stack #5" onto the plate stack #2 with the chevron of the first plate (53) in the stack facing right.

7) Install "stack #3" onto the plate stack #5 with the chevron of the first plate (22) in the stack facing left.

8) Install "stack #4" onto the plate stack #3 with the chevron of the first plate (32) in the stack facing left.

9) Install plate 5 with the chevron facing left.

10) Install plate 30 with the chevron facing right.

11) Install plate 31 with the chevron facing left.

12) Install plate 68 with the chevron facing right.

NOTE:
Chevron A is this orientation with the chevron Pointing or facing right. (Image 1.1.1)